A brush head (10) and a method (200) for manufacturing a brush head. The method (200) includes stamping (220) a plurality of openings (62) into a strip or roll of backing material (60). A bristle tuft (21) is inserted into each of the openings in the backing material. A proximal end (23) of each bristle tuft is bonded to a proximal side (63) of the backing material to create a merged proximal end head portion (26). Excess portions of the backing material are removed to form a plurality of carrier elements (24) about the openings from the backing material. The carrier elements form a plurality of merged tuft assemblies (20). A platen (42) of a neck (40) is positioned in relation to the merged tuft assemblies. A matrix material (30) is injected around the platen and the merged tuft assemblies to at least partially encompass the platen and the carrier elements of the merged tuft assemblies.

A brush head (10) and a method (200) for manufacturing a brush head. The method (200) includes stamping (220) a plurality of openings (62) into a strip or roll of backing material (60). A bristle tuft (21) is inserted into each of the openings in the backing material. A proximal end (23) of each bristle tuft is bonded to a proximal side (63) of the backing material to create a merged proximal end head portion (26). Excess portions of the backing material are removed to form a plurality of carrier elements (24) about the openings from the backing material. The carrier elements form a plurality of merged tuft assemblies (20). A platen (42) of a neck (40) is positioned in relation to the merged tuft assemblies. A matrix material (30) is injected around the platen and the merged tuft assemblies to at least partially encompass the platen and the carrier elements of the merged tuft assemblies.

The method for manufacturing a makeup brush includes: molding a ferrule and welding bristles to the ferrule. The ferrule includes a ferrule inner end; a ferrule outer end; a ferrule body; an interior; and a well. The well has a well base parallel to the ferrule outer end. The well base has an inner side and an outer side. The step of welding the bristles includes the steps of disposing the bristles in contact with the outer side of the well base and exposing the inner side of the well base to welding.

The method for manufacturing a makeup brush includes: molding a ferrule and welding bristles to the ferrule. The ferrule includes a ferrule inner end; a ferrule outer end; a ferrule body; an interior; and a well. The well has a well base parallel to the ferrule outer end. The well base has an inner side and an outer side. The step of welding the bristles includes the steps of disposing the bristles in contact with the outer side of the well base and exposing the inner side of the well base to welding.

A personal-care applicator comprises at least one stem having a proximal end including a handle and a distal end opposite to the proximal end and at least one bristled component attached to the stem, wherein the bristled component comprises a carrier and a plurality of bristles ultrasonically welded to the carrier and outwardly extending therefrom according to a pre-determined pattern, wherein the elongated carrier and the at least first plurality of bristles comprise ultrasonically compatible materials, and wherein the bristles are ultrasonically bonded to the carrier through a direct ultrasonic bond between a surface of the carrier and a lengthwise portion of each of the bristles. Process comprises providing at least one elongated stem having a proximal end and a distal end, providing the at least one bristled component, and attaching the at least one bristled component to the at least first stem.

A personal-care applicator comprises at least one stem having a proximal end including a handle and a distal end opposite to the proximal end and at least one bristled component attached to the stem, wherein the bristled component comprises a carrier and a plurality of bristles ultrasonically welded to the carrier and outwardly extending therefrom according to a pre-determined pattern, wherein the elongated carrier and the at least first plurality of bristles comprise ultrasonically compatible materials, and wherein the bristles are ultrasonically bonded to the carrier through a direct ultrasonic bond between a surface of the carrier and a lengthwise portion of each of the bristles. Process comprises providing at least one elongated stem having a proximal end and a distal end, providing the at least one bristled component, and attaching the at least one bristled component to the at least first stem.

A toothbrush head includes a cleaning element carrier and one or more bristle tufts, each consisting of a plurality of bristle filaments connected to one another via a fuse ball. The fuse balls are embedded in the cleaning element carrier such that the balls are completely enclosed and the bristle filaments protrude from the carrier's front surface. At least two fuse balls are located at different levels in the carrier.

A cleaning element carrier for a toothbrush in a form of a disk has a back surface including a central depression covering at least 70% of the back surface and forming an edge at the border. The carrier's front surface includes at least one protrusion so that the front surface comprises two levels, wherein the area covered by the depression is larger than the area covered by the protrusion.

A method for producing a toothbrush head comprises providing at least two bristle tufts that differ in at least one property; arranging the tufts in a hole-perforation plate comprising holes shaped and distributed according to the desired bristle field; arranging an energy source so that the ends of the bristle tufts and the energy source are arranged contactless, wherein the ends of the bristle tufts to be fused are arranged at different distances to the energy source and are adjusted according to the different property; applying energy to the ends of the bristle tufts until fuse balls are formed; transferring the bristle tufts to a subsequent process position, wherein the distance of the fuse ball of at least one bristle tuft to the hole-perforation plate is different from the distance of said fuse ball to the hole-perforation plate in the fusing position before; over-molding of the fuse balls of the bristle tufts with plastic material thereby forming the brush head or the part (10) thereof.

A method for producing a toothbrush head, comprising: providing at least two filament containers, each comprising a supply of loose filaments that differ in at least one of their property selected from material, diameter, cross-section, shape, and presence of additives and/or coating; picking bristle tufts from the containers and arranging them in a perforation plate comprising holes shaped and distributed according to a desired bristle field of the brush head to be produced; arranging an energy source and the ends of the tufts in a contactless arrangement, wherein the ends of the tufts to be fused are at different distances from the energy source, and wherein the distance is adjusted according to the at least one property; applying energy to the ends of the tufts until fuse balls are formed thereon; transferring the tufts to a molding position, wherein a distance between at least one fuse ball and the front surface is different from the distance between the bottom edge of said fuse ball and the front surface in the fusing position; over-molding the fuse balls with molten plastic material thereby forming a cleaning element carrier; transferring the cleaning element carrier to a brush head mold and injecting molten plastic material into the brush head mold forming a toothbrush head, wherein the cleaning element carrier is over-molded thereby and the tufts are still located in the perforation plate.